Deformable towers useful for assembly of suspensions used in a data storge drive

ABSTRACT

An actuator assembly for supporting a read/write device in an information storage device having an actuator arm having at least one tower protruding from a first surface of the actuator arm, a loadbeam having at least one tower receiving means for receiving the at least one tower, wherein the at least one tower is shaped to extend into the at least one tower receiving means when the loadbeam is joined with the actuator arm, and wherein the tower and tower receiving means are configured such that deforming the at least one tower when within the at least one tower receiving means provides a deformation interference between the at least one tower and the at least one tower receiving means that reduces movement of the tower receiving means relative to the tower.

REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. application Ser. No.09/950,267, filed Sep. 10, 2001, and entitled DEFORMABLE TOWERS USEFULFOR ASSEMBLY OF SUSPENSIONS USED IN A DATA STORAGE DRIVE, which claimsthe benefit of U.S. Provisional Application No. 60/231,893, filed Sep.11, 2000, which are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

[0002] The present invention relates to suspensions or suspensionassemblies, at least a portion of which may be assembled usingtechniques not primarily reliant on welding, brazing, or the use of anadhesive.

BACKGROUND

[0003] In a dynamic storage device, a rotating disk is employed to storeinformation in small magnetized domains strategically located on thedisk surface. The disk is attached to and rotated by a spindle motormounted to a frame of the disk storage device. A “head slider” (alsocommonly referred to simply as a “slider”) having a magnetic read/writehead is positioned in close proximity to the rotating disk to enable thewriting and reading of data to and from the magnetic domains on thedisk. The head slider is supported and properly oriented in relationshipto the disk by a head suspension that provides forces and compliancesnecessary for proper slider operation. As the disk in the storage devicerotates beneath the slider and head suspension, the air above the disksimilarly rotates, thus creating an air bearing which acts with anaerodynamic design of the head slider to create a lift force on the headslider. The lift force is counteracted by the head suspension, thuspositioning the slider at a height and alignment above the disk which isreferred to as the “fly height.”

[0004] Some head suspensions can include a loadbeam, a flexure, and abase plate. The loadbeam normally includes a mounting region at aproximal end of the loadbeam for mounting the head suspension to anactuator of the disk drive, a rigid region, and a spring region betweenthe mounting region and the rigid region for providing a spring force tocounteract the aerodynamic lift force acting on the slider describedabove. The base plate is mounted to the mounting region of the loadbeamto facilitate the attachment of the head suspension to the actuator. Theflexure is positioned at the distal end of the loadbeam, and typicallyincludes a gimbal region having a slider mounting surface to which theslider is mounted and thereby supported in read/write orientation withrespect to the rotating disk. The gimbal region is resiliently moveablewith respect to the remainder of the flexure in response to theaerodynamic forces generated by the air bearing.

[0005] In one type of head suspension, the flexure is formed as aseparate component and further includes a loadbeam mounting region thatis rigidly mounted at the distal end of the loadbeam using conventionalmeans, such as spot welds. In such a flexure, the gimbal region extendsdistally from the loadbeam mounting region of the flexure and includes acantilever beam to which the slider is mounted. A generally sphericaldimple that extends between the loadbeam and the slider mounting surfaceof the flexure is formed in either the loadbeam or the slider mountingsurface of the flexure. The dimple transfers the spring force generatedby the spring region of the loadbeam to the flexure and the slider tocounteract the aerodynamic force generated by the air bearing betweenthe slider and the rotating disk. In this manner, the dimple acts as a“load point” between the flexure/slider and the loadbeam. The load pointdimple also provides clearance between the cantilever beam of theflexure and the loadbeam, and serves as a point about which the slidercan gimbal in pitch and roll directions in response to fluctuations inthe aerodynamic forces generated by the air bearing.

[0006] Electrical interconnection between the head slider and circuitryin the disk storage device is provided along the length of the headsuspension. Conventionally, conductive wires encapsulated in insulatingtubes are strung along the length of the head suspension between thehead slider and the storage device circuitry. Alternatively, anintegrated lead head suspension, such as that described in commonlyassigned U.S. Pat. No. 5,491,597 to Bennin et al., that includes one ormore conductive traces bonded to the loadbeam with a dielectric adhesivecan be used to provide electrical interconnection. Such an integratedlead head suspension may include one or more bonding pads at the distalend of the traces to which the head slider is attached and that provideelectrical interconnection to terminals on the head slider. Theconductive trace can also be configured to provide sufficient resiliencyto allow the head slider to gimbal in response to the variations in theaerodynamic forces.

[0007] As the number and density of magnetic domains on the rotatingdisk increase, it becomes increasingly important that the head slider beprecisely aligned over the disk to ensure the proper writing and readingof data to and from the magnetic domains. Moreover, misalignmentsbetween the head slider and the disk could result in the head slider“crashing” into the disk surface as the slider gimbals due to the closeproximity of the head slider to the rotating disk at the slider flyheight.

[0008] The joining of the loadbeam to the actuator arm and the flexureto the loadbeam have been accomplished in various ways, including spotwelding. One problem associated with spot welding is the desire to spotweld two members composed of the same material. For example, two membersmade of steel will generally be better joined together with spot weldingthan if one of the members were composed of aluminum and the other ofsteel. The same is seen when spot welding polymeric materials. This cancreate an undesirable limitation, that being, the need or motivation touse members of the same composition rather than dissimilar composition.This is undesirable because the use of dissimilar compositions can allowfor different material properties, desired interfacial relationshipbetween dissimilar materials, and/or cost reductions.

[0009] Another joining technique can include the use of a joiningmaterial or a joining member to join two members. Such techniquesinclude the use of an adhesive, a soldering material, or a mechanicalfastening piece or clip. Introduction of a joining material or member,however, can add undesired complexity to one or more aspects ofinventory, assembly, use, and repair relating to the suspension member.

[0010] Consequently, there is a need for a suspension design and/orassembly technique that addresses the above-mentioned undesirableresults. Such a design and/or assembly technique could be useful withthe above-described suspension as well as unamount-type suspensions,which include discrete arms.

SUMMARY OF THE INVENTION

[0011] The present invention addresses problems not addressed by theprior art. One embodiment of the invention includes a method for makingan actuator assembly for supporting a read/write device in aninformation storage device. It includes providing a actuator arm havingat least one tower on a first arm surface of the actuator arm. Anotherstep involves providing a loadbeam comprising tower receiving means forreceiving the at least one tower. Another step is placing the loadbeamonto the actuator arm such that the at least one tower is received bythe tower receiving means. Still another step is deforming the tower toprovide a deformation interference between the at least one tower andthe tower receiving means and reduce lifting of the loadbeam from theactuator arm where the interference occurs.

[0012] The actuator arm and the tower may be comprised of a first metaland the loadbeam is comprised of a second metal. The first metal couldbe different from the second metal. The first metal could be aluminumand the second metal could be steel, such as stainless steel.

[0013] The loadbeam can have a first loadbeam surface. The previouslynoted difference between the first and second metals prevents orcomplicates attaching the loadbeam to the actuator arm by spot welding,ultrasonically welding, or other welding of the first loadbeam surfaceto the first arm surface.

[0014] The previously-noted tower receiving means can be a firstloadbeam surface having a hole through which the at least one towerprotrudes after the placing step.

[0015] The previously noted at least one tower could include, rather, aplurality of towers. The tower receiving means can include a firstloadbeam surface having a plurality of holes through which the pluralityof towers protrude after the placing step. The hole and the tower mayeach have a generally circular shape or an elongated shape or some othershape.

[0016] The previously-noted actuator arm can further include an armregistering means. The loadbeam can further include a loadbeamregistering means. Such an arm registering means could have a first armregistering hole therethrough, and such loadbeam registering means couldhave a first loadbeam registering hole therethrough. The method couldfurther comprise the step of placing the arm and loadbeam onto anassembly fixture having a first registering member such that the firstregistering member protrudes through the first arm registering hole andthrough the first loadbeam registering hole.

[0017] The arm registering means can further have a second armregistering hole therethrough. The loadbeam registering means can have asecond loadbeam registering hole therethrough. The assembly fixture canfurther have a second registering member. The step of placing the armand loadbeam onto an assembly fixture can cause the second registeringmember to protrude through the second arm registering hole and thesecond loadbeam registering hole.

[0018] The previously-noted deforming step comprises the mechanicallydeforming the tower to provide the deformation interference. The atleast one tower can be comprised of a metal and the deforming step cancomprise melting the metal to provide the deformation interference. Themelting can be accomplished by an application of one of a laser beam,ultrasonic energy, contact with a heated member, and another heatingmeans.

[0019] Initial interference can exist between the at least one tower andthe tower receiving means before the deforming step.

[0020] Still another embodiment of the present invention includes anactuator assembly for supporting a read/write device in an informationstorage device. It can include an actuator arm having at least one towerprotruding from a first surface of the actuator arm. A loadbeam can haveat least one tower receiving means for receiving the at least one tower.The at least one tower is shaped to extend into the at least one towerreceiving means when the loadbeam is joined with the actuator arm, andwherein the tower and tower receiving means are configured such thatdeforming the at least one tower when within the at least one towerreceiving means provides a deformation interference between the at leastone tower and the at least one tower receiving means. This can reducemovement of the tower receiving means relative to the tower.

[0021] The actuator arm can have a proximal region and a distal region.The at least one tower can protrude from the first surface within thedistal region. The actuator arm can be comprised of a first metal, andthe loadbeam can be comprised of a second metal, i.e., different fromthe first. For example, the first metal can be aluminum and the secondmetal can be steel, e.g., stainless steel. The at least one tower canhave a shape and a composition such that it may be mechanically deformedto provide the deformation interference and allow for performance of theactuator assembly within the information storage device. The tower canhave a tower shape and a metal-based composition such that it may bethermally deformed to provide the deformation interference and allow forthe performance.

[0022] The tower receiving means can include a first loadbeam surfacehaving at least one hole through which the at least one tower protrudeswhen the loadbeam is placed on the actuator arm. The at least one holecan be a plurality of holes, and the at least one tower can include aplurality of towers. The tower(s) and hole(s) can be circular shaped,elongate shaped, rectangular shaped, triangular shaped, or have a morecomplex shape.

[0023] Still another embodiment of the present invention can be anactuator assembly for supporting a read/write device in an informationstorage device. It can include an actuator arm having at least one towerprotruding from a first surface of the actuator arm. The at least onetower can be configured to be deform when at least one of sufficientheat or sufficient pressure is applied thereto. A loadbeam can have afirst loadbeam surface with at least one tower hole into which the atleast one tower can be inserted. The at least one tower can be shaped toextend into the at least one tower hole when the loadbeam is joined withthe actuator arm. The tower and tower hole are configured such that anapplication of at least one of sufficient heat or sufficient pressure tothe at least one tower results in deformation of the at least one towerthat secures the loadbeam to the actuator arm. The at least one towercan include one, two, three, four, or even more towers. And, the atleast one tower hole can include a like number.

[0024] The tower(s) can, instead, be positioned on the loadbeam with theholes or other receiving means positioned on the actuator arms.Similarly, one or more towers and tower holes can be on one of thesecomponents that match up correspondingly with tower holes and towers onthe other component.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025]FIG. 1 is a cross-section, side view of an embodiment of thepresent invention, wherein components are not assembled.

[0026]FIG. 2 is a perspective view of, generally, the embodiment shownin FIG. 1, wherein components are not assembled.

[0027]FIG. 3 is a perspective view of the embodiment shown in FIG. 1,wherein components are assembled, but not yet joined.

[0028]FIG. 4 is a perspective view of the embodiment shown in FIGS. 1and 2, wherein components are joined.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0029]FIGS. 1-4 illustrate and the following description refer tophysical embodiments of the invention. In addition, the followingdescription refers to methods for making such embodiments, which methodsare embodiments of the invention in their own right.

[0030] Actuator assembly 10 is useful for supporting a read/write head12 in an information storage device (not shown). The assembly 10includes an actuator arm 14 having at least one tower 16 protruding froman arm first surface 18 of the actuator arm 14. A loadbeam 20 has atleast one tower receiving means 22 for receiving the at least one tower16. A tower 16 may be shaped to extend into a tower receiving means 22when the loadbeam 20 is joined with the actuator arm 14. The tower 16and tower receiving means 22 are configured such that deforming thetower 16 when within the at least one tower receiving means 22 providesa deformation interference between the tower 16 and the tower receivingmeans 22 that reduces movement of the tower receiving means 22 relativeto the tower 16.

[0031] The actuator arm 14 can have a proximal region 24 and a distalregion 26. A tower 16 can protrude from the first surface within thedistal region 26. The actuator arm 14 can be composed of a first metal,such as aluminum, and the loadbeam 20 can be composed of a second metal,such as steel or more specifically stainless steel. Other metals couldbe used. In addition, one or both of the actuator arm 14 and loadbeam 20can be composed of or include a polymeric material, such aspolycarbonate, polyester, polyethylene, polypropylene, polyurethane,polyimide, and a variety of other polymeric materials.

[0032] A tower 16 may have a shape and composition such that it may bemechanically deformed to provide the deformation interference and allowfor performance of the actuator assembly 10 within the informationstorage device. A tower may be thermally deformed, that is, deformedpartly or entirely through the application of heat to the tower. Theapplication of heat can be in conjunction with other actions to deform,such as the application of pressure to deform the tower 16.

[0033] The tower 16 can be formed as part of the arm 14, i.e., integral,when fabricating the arm 14, e.g., by machining, stamping, or etching.Or, the tower 16 can be formed as a component separate from andattachable to the arm 14, e.g., welded, brazed, glued, or other knownattachment processes.

[0034] A tower receiving means 22 may be structurally provided by afirst loadbeam surface 28 having at least one tower hole 30 throughwhich the a tower 16 protrudes when the loadbeam 20 is placed on theactuator arm 14. One, two, three, four, or more holes 30 and acorresponding number of towers 16 may be used. A tower hole 30 and atower 16 may each have a generally circular shape, although other shapescan be used. For example, oval, rectangular, triangular, or other morecomplex shapes may used instead. Also, it is not necessary that theshape of a tower hole 30 match the shape of a tower 16.

[0035] The actuator arm 14 can further include an arm registering meansand the loadbeam 20 can further include a loadbeam registering means.The arm registering means can have an arm registering hole 32therethrough. The loadbeam registering means can have a first loadbeamregistering hole 34 therethrough. The arm 14 and loadbeam 20 can beplaced onto an assembly fixture 36 that has a registering member 38 suchthat the first registering member protrudes through the arm registeringhole 32 and through the first loadbeam registering hole 34.

[0036] The arm registering means can further have additional armregistering holes 32 therethrough, and the loadbeam registering meanscan have additional loadbeam registering holes 34 therethrough, to workin conjunction with additional registering members 38 in the assemblyfixture 36. Placing the arm 14 and loadbeam 20 onto an assembly fixture36 can cause the additional registering member or members 38 to protrudethrough the additional arm registering hole or holes 32 and theadditional loadbeam registering hole or holes 34.

[0037] A method for making an actuator assembly for supporting aread/write device in an information storage device can include providingthe actuator arm 14 with one or more towers 16 on an arm first surface18 of the actuator arm 14. Another step can be to provide a loadbeam 20having tower receiving means 22 for receiving the on or more towers 16.The loadbeam 20 may be placed onto the actuator arm 14 such that eachtower 16 is received by tower receiving means 22. Then, each tower 20may be deformed to provide a deformation interference between each tower16 and a tower receiving means 22 to reduce lifting of the loadbeam 20from the actuator arm 14 where the interference occurs.

[0038] The method can further include the step of placing the arm 14 andloadbeam 20 onto an assembly fixture 36 having the one or moreregistering members 38 such that they protrude through the one or moreregistering holes 32 of the arm 14 and through one or more registeringholes 34 of the loadbeam 20.

[0039] Separate from or together with the registering holes and membersjust noted, the one or more towers 16 and corresponding tower receivingmeans 22 can provide registration of the arm 14 relative to the loadbeam20 during assembly of the actuator assembly 10.

[0040] The deforming step can include mechanically deforming the tower16 to provide the deformation interference. For example, the tower 16can be struck by, for example, known coining members (not shown). Theshape of the tower 16 and such coining members can be chosen such thatthe strike by the coining member causes the tower 16 to deform andinterfere with the receiving means 22. For example, the coining membercan have a pointed striking surface.

[0041] The deforming step can instead rely on the application of heat tomelt and deform a portion of a tower 16, which can be accomplished byknown applications of a laser beam, ultrasonic energy, contact with aheated member, and other heating means. In addition, the deforming stepcan include the combination of the above noted applications of pressureand heat.

[0042] The assembly methods described above can be augmented with othersteps. For example, in conjunction with the deforming step, another stepcould involve the application of an adhesive or cement to one or morejoining points. Such adhesive or cement could, for example, beelectrically conductive.

[0043] Alternative embodiments in one sense can have or not have aninitial interference between the at least one tower and the towerreceiving means before the deforming step is carried out. With respectto an initial interference embodiment, the tower 16 and tower receivingmeans 22, for example, can be configured such that the tower 16 may bepress-fit into or through the tower receiving means 22.

[0044] The disclosure herein discloses embodiments of the invention, butshould not be taken as limited to all of the details thereof, asmodifications and variations thereof may be made without departing fromthe spirit or scope of the invention. For example, the disclosureinvolves joining a loadbeam 20 to an actuator arm 14. And, as shown inFIGS. 3 and 4, the flexure 42 can be similarly joined to the actuatorarm 14 using of towers 16 and tower receiving means 22. The flexure 42could similarly be attachable to the loadbeam 20.

[0045] Further, the invention could be applied to suspensions orsuspension assemblies having, for example, discrete arms (referred to bysome as unamount suspensions). The invention can also apply to othersuspensions or suspension assemblies. Still further, the towers 16 on anactuator arm 14 and received by a receiving means 22 on a loadbeam 20could be rearranged such that one or more of the towers are on theloadbeam 20 and the receiving means 22 on the arm 14.

[0046] Further, the disclosure provides a solution for when componentsto be connected are of dissimilar metals. For example, on one hand, itcan advantageous for performance and/or cost purposes to use an aluminumactuator arm and a steel loadbeam or vice versa, and on the other hand,the use of dissimilar metals can eliminate or reduce the effectivenessof an assembly process such as the spot welding or another process forsecuring the surface of one component to the surface of anothercomponent without the need to use an additional connecting material. Thedisclosed tower 16, tower receiving means 22, and deforming methodenable the connecting of components of such dissimilar metals. Thoughthe preceding refers to components of dissimilar metals, it iscontemplated that the arm 14, loadbeam 20, and flexure 42 may beconstructed of non-metal materials in conjunction with metal materials,e.g., a steel loadbeam 20 partially or entirely coated with a polymericmaterial.

[0047] The disclosed invention may be used in conjunction with knowndevices, article, compositions of matter, and methods. Further, theinvention can be a combination of two or more of the concepts disclosedherein. The invention may be particularly applicable to data storagedrive devices, but may also be applicable to other devices. Further,publicly known information regarding the making and using of componentsand methods described herein augment this disclosure, includinginformation disclosed in patents and published patent applications. Forexample, U.S. Pat. No. 6,061,896 describes components and methods formaking and/or assembling suspensions and/or actuator assemblies thatcould be used with the invention described or claimed herein; thispatent is hereby incorporated by reference.

1. A method for making an actuator assembly for supporting a read/writedevice in an information storage device, comprising the steps of:providing a actuator arm comprising at least one tower on a first armsurface of the actuator arm; providing a loadbeam comprising towerreceiving means for receiving the at least one tower; placing theloadbeam onto the actuator arm such that the at least one tower isreceived by the tower receiving means; deforming the tower to provide adeformation interference between the at least one tower and the towerreceiving means and reduce lifting of the loadbeam from the actuator armwhere the interference occurs.
 2. The method of claim 1, wherein theactuator arm and the tower are comprised of a first metal and theloadbeam is comprised of a second metal, wherein the first metal isdifferent from the second metal.
 3. The method of claim 1, wherein thefirst metal is aluminum and the second metal is steel.
 4. The method ofclaim 1, wherein the loadbeam has a first loadbeam surface, and whereinthe difference between the first and second metals prevent attaching theloadbeam to the actuator arm by spot welding, ultrasonically welding, orother welding of the first loadbeam surface to the first arm surface. 5.The method of claim 1, wherein, before the deforming step, the loadbeammay lift from the actuator arm where the tower is received by the towerreceiving means.
 6. The method of claim 1, wherein the tower receivingmeans comprises a first loadbeam surface having a hole through which theat least one tower protrudes after the placing step.
 7. The method ofclaim 6, wherein the at least one tower comprises a plurality of towers,wherein the tower receiving means comprises a first loadbeam surfacehaving a plurality of holes through which the plurality of towersprotrude after the placing step.
 8. The method of claim 6, wherein thehole and the tower each have a generally circular shape.
 9. The methodof claim 6, wherein the hole and the tower each have a generallyelongated shape.
 10. The method of claim 1, wherein the actuator armfurther comprises an arm registering means and the loadbeam furthercomprises a loadbeam registering means.
 11. The method of claim 10,wherein the arm registering means having an first arm registering holetherethrough and wherein the loadbeam registering means having a firstloadbeam registering hole therethrough, wherein the method furthercomprises the step of placing the arm and loadbeam onto an assemblyfixture having a first registering member such that the firstregistering member protrudes through the first arm registering hole andthrough the first loadbeam registering hole.
 12. The method of claim 11wherein the arm registering means further has a second arm registeringhole therethrough, wherein the loadbeam registering means has a secondloadbeam registering hole therethrough, wherein the assembly fixturefurther has a second registering member, wherein the step of placing thearm and loadbeam onto an assembly fixture causes the second registeringmember to protrude through the second arm registering hole and thesecond loadbeam registering hole.
 13. The method of claim 1, wherein theat least one tower and the tower receiving means combine to provideregistration of the arm relative to the loadbeam during assembly of theactuator assembly.
 14. The method of claim 1, wherein the deforming stepcomprises the step of mechanically deforming the tower to provide thedeformation interference.
 15. The method of claim 1, wherein the atleast one tower is comprised of a metal and the deforming step comprisesmelting the metal to provide the deformation interference, wherein themelting is accomplished by an application of one of a laser beam,ultrasonic energy, contact with a heated member, and another heatingmeans.
 16. The method of claim 1, wherein initial interference betweenthe at least one tower and the tower receiving means exists before thedeforming step.